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!ow I'portant 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
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Calls Per Hour
Call Duration an
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Page 52
1 2 ! # 5 + / 1 4 15 11 12 1! 1# 15
Process ,nputs Total
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3ating of
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Cause > ,**ect Matri? Cause > ,**ect Matri?
PAM&$ ,nformation Sheet
PAM&$ Dum'erG
Process DameG
Process 3esponsi'ilityG
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PAM&$ 2ey DateG
PAM&$ (rigination DateG
PAM&$ 3e*ision DateG
Core Team Mem'ersG
Potential Aailure Moes an
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Sheet8
Potential Aailure Moes an
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Page 5#
Prepare 'yG Page QQQQ of QQQQ
3esponsi'leG AM&$ Date 6(rig8 QQQQQQQQQQQQQQ 63e*8 QQQQQQQQQQQQQ
Process Step Potential Failure Mo-e Potential Failure ,**ects Potential Causes Current Controls 0esp5 Actions Taken
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,n -hat -ays oes the 2ey
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Fhat is the impact on the 2ey
(utput "aria'les 6Customer
3e;uirements8 or internal
re;uirements.
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Fhat are the existing controls an
proceures 6inspection an test8
that pre*ent eith the cause or the
Aailure Moe. Soul- inclu-e an
SOP nu'#er5
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Fhat are the actions
for reucing the
occurrance of the
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etection. Soul-
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recalculate 3PD. Be
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Process 7 Pro-uct
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Process 7 Pro-uct
Failure Mo-es an- ,**ects Anal+sis
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ASe*erity
Page 55
&ffect CriteriaG Se*erity of &ffect Define 3anking
15
4
"ery High 1
High /
Moerate +
Co- 5
"ery Co- #
Minor !
"ery Minor 2
Done Do effectB 1
Ha%arousG
Fithout Farning
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in*ol*es noncompliance -ith go*ernment regulationB Aailure -ill occur WIT!O2T
-arningB
Ha%arousG Fith
Farning
May enanger operatorB Aailure moe affects safe *ehicle operation an > or
in*ol*es noncompliance -ith go*ernment regulationB Aailure -ill occur WIT!
-arningB
Ma)or isruption to prouction lineB 155J of prouct may ha*e to 'e scrappeB
"ehicle > item inopera'le< loss of primary functionB Customer *ery issatisfieB
Minor isruption to prouction lineB Prouct may ha*e to 'e sorte an a portion
6less than 155J8 scrappeB "ehicle opera'le< 'ut at a reuce le*el of
performanceB Customer issatisfieB
Minor isruption to prouction lineB $ portion 6less than 155J8 may ha*e to 'e
scrappe 6no sorting8B "ehicle > item opera'le< 'ut some comfort > con*enience
item6s8 inopera'leB Customers experience iscomfortB
Minor isruption to prouction lineB 155J of prouct may ha*e to 'e re-orkeB
"ehicle > item opera'le< 'ut some comfort > con*enience item6s8 opera'le at
reuce le*el of performanceB Customer experiences some issatisfactionB
Minor isruption to prouction lineB The prouct may ha*e to 'e sorte an a
portion 6less than 155J8 re-orkeB Ait > finish > s;ueak > rattle item oes not
conformB Defect notice 'y most customersB
Minor isruption to prouction lineB $ portion 6less than 155J8 of the prouct may
ha*e to 'e re-orke on:line 'ut out:of:stationB Ait > finish > s;ueak > rattle item oes
not conformB Defect notice 'y a*erage customersB
Minor isruption to prouction lineB $ portion 6less than 155J8 of the prouct may
ha*e to 'e re-orke on:line 'ut in:stationB Ait > finish > s;ueak > rattle item oes not
conformB Defect notice 'y iscriminating customersB
A(ccurance
Page 5+
Pro#a#ilit+ o* Failure Possi#le Failure 0ates Cpk 0ankin)
.er+ !i)( R 5B!! 15
Aailure is almost ine*ita'le 1 in ! 4
1 in 1 1
processes that ha*e often faile 1 in 25 /
1 in 15 +
pre*ious processes -hich ha*e 1 in #55 5
1 in 2<555 #
1 in 15<555 !
1 in 155<555 2
1
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5B!!
!i)( =enerally associate -ith
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experience occasional failures<
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associate -ith almost ientical
processes
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failures e*er associate -ith almost
ientical processes
1 in 1<555<555 1B+/
ADetection
Page 5/
Detection 0ankin)
Al'ost I'possi#le Test content etects R 15 J of failures 15
.er+ 0e'ote Test content must etect 15 J of failures 4
0e'ote Test content must etect 12B5 J of failures 1
.er+ Low Test content must etect 15 J of failures /
Low Test content must etect 1/B5 J of failures +
Mo-erate Test content must etect 45 J of failures 5
Mo-eratel+ !i) Test content must etect 42B5 J of failures #
!i) Test content must etect 45 J of failures !
.er+ !i) Test content must etect 4/B5 J of failures 2
Al'ost Certain Test content must etect 44B5 J of failures 1
Criteria( Liklioo- te e?istence o* a -e*ect will #e
-etecte- #+ test content #e*ore pro-uct a-"ances
to ne?t or su#se=uent process
Core TeamG Date 6(rig8G
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